US 11,806,979 B2
Polymer composite building product and method of fabrication
John Pacanovsky, Cary, NC (US); Ibrahim Ali Ozkan, Carrboro, NC (US); Silvester Pius Motha, Morrisville, NC (US); Zhi-Jie Liu, Raleigh, NC (US); and Christopher David Strom, Cary, NC (US)
Assigned to Ply Gem Industries, Inc., Cary, NC (US)
Filed by PLY GEM INDUSTRIES, INC., Cary, NC (US)
Filed on Dec. 24, 2020, as Appl. No. 17/133,721.
Application 17/133,721 is a continuation in part of application No. 17/079,897, filed on Oct. 26, 2020.
Claims priority of provisional application 62/931,479, filed on Nov. 6, 2019.
Prior Publication US 2021/0129484 A1, May 6, 2021
This patent is subject to a terminal disclaimer.
Int. Cl. B32B 5/26 (2006.01); B32B 5/08 (2006.01); B32B 27/12 (2006.01); B32B 27/26 (2006.01); B32B 7/06 (2019.01); B32B 37/00 (2006.01); B32B 37/02 (2006.01)
CPC B32B 5/26 (2013.01) [B32B 5/08 (2013.01); B32B 7/06 (2013.01); B32B 27/12 (2013.01); B32B 27/26 (2013.01); B32B 37/0053 (2013.01); B32B 37/02 (2013.01); B32B 2255/02 (2013.01); B32B 2255/26 (2013.01); B32B 2262/101 (2013.01); B32B 2305/28 (2013.01); B32B 2305/30 (2013.01); B32B 2305/38 (2013.01); B32B 2305/72 (2013.01); B32B 2305/74 (2013.01); B32B 2307/102 (2013.01); B32B 2307/304 (2013.01); B32B 2307/514 (2013.01); B32B 2307/732 (2013.01); B32B 2315/085 (2013.01); B32B 2419/00 (2013.01)] 40 Claims
OG exemplary drawing
 
1. A polymer composite building product, the building product comprising:
a front face for facing outward from the building and a rear face for placement adjacent a surface of the building;
a first fiber sheet comprising a total thickness T;
a thermoset polymer coating resin, the polymer coating resin infiltrating only about 2-3 mils (TR) of the total thickness T of the first fiber sheet overlaid onto the polymer coating resin, wherein the building product front face is comprised of the first fiber sheet partially infiltrated with the polymer coating resin, the front face having a surface energy of greater than 38 dynes/cm;
a core comprised of a closed cell admixture composition with a filler loading at least 74 percent by total weight of the admixture, the admixture further comprising a first longitudinally extending surface and an opposed second longitudinally extending surface, the first longitudinally extending surface of the admixture infiltrating a remaining thickness (T-TR) of the first fiber sheet not infiltrated with polymer coating resin; and
a second fiber sheet comprising a second sheet areal weight in the range of 140-170 g/m2 as well as an upper face and a lower face, the admixture penetrating and enmeshed through the entire thickness of the second fiber sheet, wherein the upper face of the second fiber sheet and the admixture enmeshed into the upper face of the second fiber sheet comprising the rear face of the building product.